US8251732B2 - Power input electrical connector - Google Patents

Abstract

A wiring harness electrical connector is provided having a detachable and re-attachable mounting system to permit the attachment of the connector on a frame surface of a semi-trailer, or workpiece, from the rear or interior side of the of the frame or workpiece without disruption to the integrally formed and moisture proof encasing of the connector.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Application No. 61/359,189 filed Jun. 28, 2010 and titled Power Input Electrical Connector.

FIELD OF THE INVENTION

This application relates to the field electrical connectors. More particularly, this application relates to connectors used to connect the electrical wiring harnesses of over-the-road trailers, and in particular, trailers connected in double trailer arrangement.

BACKGROUND OF THE INVENTION

Semi-trailer tractor trucks also known as a semi, or tractor-trailer, will frequently be configured to tow a second semi-trailer behind the first in a configuration known as a “double trailer”. In such a configuration it is necessary that the tail lamps, running lamps, brake lights, and signal lights of the towed trailer be connected into the tractor so proper illumination and turn and brake signals are operating on the rear-most trailer. This is typically accomplished by providing a wiring harness that travels the length of the first trailer to communicate electrical signals generated by the tractor to the rear-most trailer. The wiring harness allows the rear-most trailer to be connected into the electrical system of the tractor thereby receiving the electrical impulses that cause illumination of the tail lamps, running lamps, brake lights, and signal lights of the towed trailer. The wiring harness must be affixed to the trailer and at the front and/or rear of the trailer. The end terminal or socket of the wiring harness must be installed into a portion of the frame of the trailer. Generally, such installation comprises the placement of the receptacle or socket (typically known as an SAE standard J560 connector) within a round hole or void that has been made in a front or rear metal frame piece of the trailer. It will be appreciated that a first end of the wiring harness has an electrical connector located in an opening on the forward facing surface of the trailer, (or workpiece) and is commonly referred to as the “Nose Plug.” A second electrical connector is located in an opening on the rearward facing surface of the trailer and may be referred to as the “Tail Plug.” Both plugs or receptacle or sockets are defined in SAE specification J560. The connector at the rear of the trailer is suitable for connecting another tandem trailer and serves as the power output connector to the trailer in-tow or dolly in-tow.

The challenge in trailer wiring is ensuring a waterproof seal at the trailer's power connector. The electrical connector is exposed to all forms of weather and highway driving speeds and vibrations. This environment and these conditions make it essential that any connector be sealed against the elements and that the integrity of such sealing against the elements be maintained during installation to avoid corrosion of the connector and wiring harness. Generally, this requirement for excluding moisture and dirt has resulted in wiring harnesses that are fully formed with integral receptacles or socket and with molded plastic covers that extend the length of the wiring harness and the receptacles. Therefore, installation of a wiring harness requires either insertion of one end of the harness through a mounting hole in the trailer frame and pulling the 30 to 60 feet of wire through the hole or having a connector that can be mounted in the hole from the back-side of the hole. The first of these installation methods can result in the scraping and cutting of the wiring harness on the edges of the metal in which the hole or void is made.

Therefore, it would be beneficial to have a receptacle or socket that allows for rear installation of the socket onto the trailer frame to avoid pulling the whole of the wiring harness through the hole in the trailer frame. It would be a further benefit if the socket is integrally sealed against moisture with the wires or electrical leads that are attached to the connector. It would be a further benefit if the means for attaching the connector avoids the creation of entry points for moisture of areas that will retain moisture and lead to corrosion of the electrical components and connections of the socket or connector.

SUMMARY OF THE INVENTION

The present electrical connector comprises a standard J560-type receptacle or connector with a sealed, molded plastic unitary cover that extends over the length of the wire bundle and over the connector body to provide a moisture proof housing. The front of the connector is provided with surrounding collar that is separable into at least two segments, a detachable retaining clip segment and a non-detachable lip segment. The detachable retaining clip, when removed, reduces the overall dimension of the connector exterior to permit the insertion of the connector through a hole, void or opening in a trailer frame that is dimensioned to receive a SAE standard J560 connector therein. Once the non-detachable lip segment of the connector is inserted through the hole, void or opening in the trailer frame the retaining clip may be reattached to form a collar to retain and secure the connector within the a hole, void or opening and to the trailer frame.

DESCRIPTION OF THE DRAWINGS

Preferred embodiments of the invention, illustrative of the best modes in which the applicant has contemplated applying the principles, are set forth in the following description and are shown in the drawings and are particularly and distinctly pointed out and set forth in the appended claims.

FIG. 1 shows a front and right side perspective view of the assembled electrical connector having theretainer clip12 in position on the connector body to form a collar;

FIG. 2 is a cross-section view taken along line2-2 ofFIG. 1 and showingretainer clip12 in position onconnector body14 withterminals16 inserted intoapertures18 ofconnector body14 and showing awiring harness20 havingconductors22 extending therefrom and connecting withterminals16 surroundingwiring harness20 andconnector body14 is over-moldcable retainer24;

FIG. 3 is a front and right side perspective view ofelectrical connector10 in a partially exploded view showingretainer clip12 separated fromconnector body14 and showingelectrical connector10 in an installed environment in which a void orhole26 is provided in awork piece28 andconnector body14 is passed throughvoid26 to then allow installation ofretainer clip12 on the opposite side of the bulkhead fromcable retainer24;

FIG. 4 shows a rear and left side perspective view of theconnector body14 ofFIG. 1 with the terminals wiring harness retainer clip and cable retainer removed and showing the sevenapertures18 of one embodiment for receivingterminal16 therein and showingcavity30 onconnector body14, which receivesfinger32 that projects from retainer clip12 (seeFIG. 3) and showingshoulder34 whichcontacts retainer clip12 to supportretainer clip12 and showingseating trough36 onconnector body14, which receivesridge38 of retainingclip12 therein to assist inretaining connector body14 withinvoid26 ofbulkhead28. Also shown aregrooves40 at the rear ofapertures18, which receiveterminal retention tabs42 ofterminal16 therein;

FIG. 5 shows a front elevation view ofconnector body14 showingapertures18 therein which receiveterminals16 and showingflange receivers44 therein which receivespring flanges46 ofterminal16 to prevent rearward movement ofterminal16 withinconnector body14.Access voids48 are shown which allow the plastic material that forms over-moldcable retainer24 to flow throughconnector body14 during formation of the over-mold cable retainer;

FIG. 6 shows a front top and left side perspective view ofretainer clip12 with securingapertures50 therein;

FIG. 7 shows a rear bottom and right side perspective view ofretainer clip12;

FIG. 8 shows a front top and right side perspective view ofterminal16;

FIG. 9 shows a front and left side perspective view ofelectrical connector10 with retainingclip12 removed; and

FIG. 10 shows a front and right side exploded view ofelectrical connector10 and also showingconnector seal52 which is formed simultaneously with the formation of over-moldcable retainer24 as plastic material forming over-moldcable retainer24 is forced throughaccess voids48 inconnector body14.

DESCRIPTION OF THE PREFERRED EMBODIMENT

As required, detailed embodiments of the present inventions are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention, which may be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention in virtually any appropriately detailed structure.

Referring now toFIG. 1,electrical connector10 is shown completely assembled but not shown installed as it would be for use in a structure requiring an electrical connector.Electrical connector10 is generally comprised of aretainer clip12 which connects to aconnector body14 with theretainer clip12 being removable and installable as needed to permit insertion ofconnector body14 through an aperture or hole in a structure such as a truck trailer.

Referring now toFIG. 10, the component parts ofelectrical connector10 and their relationships to one another will be described. InFIG. 10,electrical connector10 is shown in an exploded view.Connector clip12 is shown space above the position it connects to onconnector body14.Terminals16 are shown just prior to their insertion intoterminal apertures18 ofconnector body14. Awiring harness20 havingconductors22 is shown in position for connection toterminals16. Over-moldcable retainer24 is shown removed fromconnector body14 andconnector seal52 is shown separated fromconnector body14. It will be appreciated by those skilled in the art that after the assembly of wiring harness andconductors22 toterminal16 and the insertion ofterminal16 intoconnector body14 that a liquid plastic material is then injected into a mold form containing the connector body and the terminals and the wiring harness. A liquid plastic material is injected to form the shape of over-moldcable retainer24. During the formation process of over-moldcable retainer24, a portion of the injected liquid plastic is allowed to pass throughaccess voids48 in connector body14 (best seen inFIG. 5) to provide the formation ofconnector seal52 simultaneously with the formation of over-moldcable retainer24. Therefore a simultaneously molded unitary structure comprised of over-moldcable retainer24 andconnector seal52 is constructed. It will be appreciated by those skilled in the art that the presence ofconnector seal52 prevents moisture and debris from coming in contact with the terminals ofelectrical connector10 when a complementary male connector is inserted into the femaleelectrical connector10 shown in the present embodiment.

Referring now toFIG. 2, the construction ofelectrical connector10 is shown in cross-section view wherein it may be seen thatterminals16 are inserted intoapertures18 which are provided withinconnector body14. As will be discussed hereinafter,terminal16 are securely mounted withinapertures18 and structures are present to prevent both rotation of16 withinapertures18 and the rearward movement ofterminals16 out ofapertures18 after the insertion ofterminal16 into the back end or rear ofconnector body14. It is shown inFIG. 2 thatconductors22 are connected toterminal16 with such connection being made by soldering orwelding connectors22 to the surface of a flat spade extension from the rear ofterminal16, or alternatively,conductor22 may be crimped into connection withterminal16 using acrimp connection54 as is shown inFIG. 8.

Still referring toFIG. 2,conductors22 are contained withinwiring harness20 which serves to maintain the seven conductors of the present embodiment in a single manageable group.Retainer clip12 is shown in position onconnector body14 inFIG. 2 and the entirety ofconnector body14 havingterminal16 therein withconductors22 connected thereto and the wiring harness grouping ofconductors22 all being surrounded by the plastic ofover-mold cable retainer24 as a result of the injection molding process to produceover-molding cable retainer24 andconnector seal52.

Referring now toFIG. 3, the method of use and installation ofelectrical connector10 will be described. One typical use ofelectrical connector10 is to install the electrical connector into a pre-existing wall or bulkhead of a vehicle such as a truck trailer. In a typical application, electrical connectors of the type to whichelectrical connector10 belongs are installed in tandem tractor-trailer configurations wherein power and signal light and brake light connections must be communicated from a first trailer to a second trailer. In view of the long length of the wiring harnesses used in such an application and the need to have a weather resistant cable connection it is advantageous to avoid feeding a long length of wiring harness through an aperture. Also, it is advantageous to avoid disassembly of the electrical connector to install it on the vehicle or bulkhead or workpiece involved. The reason for this will be apparent to those skilled in the art. The feeding of long lengths of wiring harness through apertures can result in the scraping of the covering of the wiring harness and potential cutting of the wiring harness and insulating material around conductors thereby compromising the integrity of the wiring harness. The assembly and disassembly of the electrical connector to permit its mounting on the vehicle or workpiece will compromise the weather resistant nature of the assembly such assembly and disassembly requires removable parts with connecting crevices which can permit the intrusion of dirt and moisture into the device thereby compromising the quality of the electrical connections. Therefore, the present structure is designed with these issues in mind to provide a complete sealed integrally formed structure which does not require assembly or disassembly of the electrical connector and related components for installation into the workpiece or vehicle. Further, the manner of installation avoids the need to feed the entire length of wiring harness through an aperture which may have sharp edges which could scrape and cut and compromise the quality of the insulation on the conductors.

InFIG. 3, a workpiece or bulkhead orvehicle surface28 is shown in broken lines indicating it to be environmental structure. Also is shown a void or hole oraperture26 in the workpiece which is sized to permit the passage ofconnector body14 ofelectrical connector10 there-through once retainingclip12 has been removed fromconnector body14. Also shown inFIG. 3 aresecondary voids56, which permit insertion of a fastener therethrough to enable securing ofelectrical connector10 to bulkhead28 once installation and assembly ofelectrical connector10 is complete. Upon insertion of electrical connector10 (without retaining clip12) throughvoid26 inbulkhead28,lip58 extending downwardly from the bottom ofconnector body14 becomes positioned on the opposite side of the void26 from the remainder ofconnector body14.Lip58 serves to properly orient connector body withinvoid26 to position the structures ofconnector body14 which connectably mate with retainingclip12 on the outside of the void26. It will be noted that for purposes of this description, the location “outside the void” will be taken to mean on a first side of thebulkhead28 in which the void26 is established and the phrase “inside the void” will mean the position on a second side ofbulkhead28. Upon seating oflip58outside void26, and on a first side ofbulkhead28, it will be possible to connectretainer clip12 to those portions ofconnector body14, which also are positioned outside ofvoid26 by the seating oflip58 againstbulkhead28 outside ofvoid26. These additional parts and features ofconnector body14 will be described hereinafter in detail, but they generally can be described as those features ofconnector body14 which are adapted to receive thereinretainer clip12 and to mate with structures on retainingclip12 to seat and lockretainer clip12 toconnector body14 and thereby to seat and lockelectrical connector10 withinvoid26 onbulkhead28 with certain features ofelectrical connector10outside void26 and certain features ofelectrical connector10 insidevoid26.

As may be seen inFIG. 3, the features that are generally insidevoid26 on a second side ofbulkhead28 areover-mold cable retainer24 andwiring harness20 andconductors22 andterminal16 andterminal apertures18 and the features that areoutside void26, on a first side ofbulkhead28, are retainingclip12,lip58,seating trough36,cavity30 andshoulder34 oflip58. Onceconnector body14 has been positioned as previously described invoid26,bulkhead28 and retainingclip12 is attached toconnector body14, the resultant structure will appear as is shown inFIG. 1 (howeverFIG. 1 does not show the environmental structure ofFIG. 3). It will be appreciated by those skilled in the art that securingapertures50 of retainingclip12 align withsecondary voids56 ofbulkhead28 to permit passage of a fastener therethrough to complete the installation ofelectrical connector10 onbulkhead28 of a vehicle or trailer or other structure.

Still referring toFIG. 3, it now can be appreciated that the structure shown inFIG. 9 are those portions ofelectrical connector10 which are manipulated as a unit for insertion throughvoid26 inbulkhead28.FIG. 9 also provides yet another view ofshoulder34 andcavity30 andseating trough36 which receivefinger32 andridge38 ofretainer clip12 and which serve to provide a positive connection betweenconnector body14 andretainer clip12 and prevent retraction ofconnector body14 back throughvoid26 inbulkhead28 once retainingclip12 is installed.

Referring now toFIGS. 4 and 5, the structure ofconnector body14 will be described in additional detail. InFIG. 4 afirst end60 ofconnector14 is shown havingterminal apertures18 therein.Terminal apertures18 receiveterminals16 andsecure terminals16 withinapertures18 bygrooves40 which receiveterminal retention tabs42. Thetabs42 engage ingrooves40 and by such connection toconnector body14 eliminate any rotational movement ofterminal16 around the longitudinal axis ofterminal16. In this manner, rotational forces on the connection betweenterminal16 andconductors22 is provided and integrity of the soldering or crimping connection betweenconductors22 andterminal16 is enhanced. Also shown inFIG. 4 are two retainingridges62 which extend outwardly from the central longitudinal axis ofconnector body14. It will be appreciated by those skilled in the art that these features operate to provide protrusions that are surrounded by the liquid plastic that is injected to formover-mold cable retainer24.Protrusions62 operate to assist in securing the connection betweencontainer body14 andover-mold cable retainer24 to prevent slippage and separation betweencontainer body14 andover-mold cable retainer24 after the formation of the cable retainer. This is of particular importance as these features are adjacent to accessvoids48 incontainer body14 which allow the flow of liquid plastic material therethrough to permit the formation ofconnector seal52 within thereceptacle area64 ofcontainer body14.

Still referring toFIG. 5, the front ofterminal apertures18 is shown.Flange receivers44 are positioned interminal apertures18.Flange receivers44 are provided to capture thereinspring flanges46 which extend fromterminal16. It can be appreciated by those skilled in the art that upon insertion ofterminal16 intoapertures18 ofconnector body14 thatspring flanges46 become slightly depressed as they move throughterminal apertures18. Upon coming into contact withflange receivers44 which are larger than the general diameter ofterminal apertures18,spring flanges46 can return to their original position and become captured withinreceivers44. This capture ofspring flanges46 withinflange receivers44 operates to prevent the subsequent rearward withdrawal of terminal16 from engagement withterminal apertures18. In this manner rearward directed stresses transmitted viawiring harness20 and/orover-mold cable retainer24 to the connection ofterminal16 withinterminal apertures18 is resisted and the integrity ofelectrical connector10 is enhanced.

Referring now toFIGS. 6 and 7,retainer clip12 will be more fully described. InFIG. 6, retainingclip12 is shown having securingapertures50 extending therethrough to permit the passage of fasteners therethrough for the securing ofelectrical connector10 onto aworkpiece28 or bulkhead of atruck28 after assembly of retainingclip12 ontoconnector body14 has been completed. Retainingclip12 is provided withridge38 which extends from retainingclip12 for connection intoseating trough36 of connector body14 (FIG. 4). It will be appreciated by those skilled in the art thatridge38 fits intoseating trough36 and therefore separate forward motion or rearward motion of retainingclip12 with respect toconnector body14 is inhibited. Also shown inFIG. 6 isfinger32 which projects outwardly fromridge38 and which is intended for reception withincavity30 onconnector body14. Ascavity30 is a further intrusion into the surface ofconnector body14 as compared to the distance of intrusion provided by seatingtrough36, it will be appreciated that asconnector clip12 is guided intoseating trough36 ofconnector body14 thatfinger32 rides along flat segment36A ofseating trough36 after whichfinger32 of retainingclip12 is forced intocavity30 onconnector body14 by retainingclip12. This forcing offinger32 intocavity30 is achieved as the insertion of retainingclip12 intoseating trough36 causes an outward expanding forced to be delivered to retainingclip12 as it passes along the track created by seatingtrough36 and flat segment36A. Uponfinger32 reachingcavity30,finger32 is pressed inwardly to relieve the outward, expansive pressure that has been delivered to retainingclip12 by movement past the diameter ofconnector body14. The forces involved here are generated by the presence of afinger32 on each side ofretainer clip12 thus providing ofopposed fingers32 on either side of retaining clip12 (best seen inFIG. 7). This gap betweenfingers32 as indicated by Arrow A is narrower than the diameter of flat segments36A on either side ofconnector body14. This different spacing therefore causes the slight expansion of retaining clip A as it is inserted ontoconnector body14 and results in the inward movement offingers32 intocavities30 of connector body A to positively capture retainingclip12 onconnector body14. As previously described, once retainingclip12 is seated and captured byconnector body14, fasteners may be passed through securingapertures50 and throughworkpiece28 to secureelectrical connector10 to the workpiece.

Referring now toFIG. 8, terminal16 will be described in greater detail.Terminal16 is formed of an electrically conductive material such as a metal and is provided withspring flanges46, which are captured withinflange receivers44 ofconnector body14.Terminal16 also is provided withterminal retention tabs42 which, upon installation ofterminal16 withinconnector body14, become inserted intogrooves40 to prevent pull out ofterminal16 withinterminal apertures18 ofconnector body14. As previously described, the function ofspring flanges46 is to provide a positive capture ofspring flanges46 withinflange receivers44 and to thereby prevent the withdrawal ofterminals16 fromterminal apertures18 ofconnector body14. InFIG. 8, the embodiment ofterminal16 is shown with acrimp connection54 which has first and second legs54A and54B which receiveconductor22 therebetween upon which legs54A can be pressed againstconductor22 to captureconductor22 therebetween for positive electrical connection.

Once the connector system is securely attached to the trailer, a power cord can be connected to a forward mounted J560 connector to provide trailer power from the tractor power. Alternatively a power cord can be attached to a rear mounted J560 connector to provide power to tandem trailer or converter dolly.

In the foregoing description, certain terms have been used for brevity, clearness and understanding; but no unnecessary limitations are to be implied therefrom beyond the requirements of the prior art, because such terms are used for descriptive purposes and are intended to be broadly construed. Moreover, the description and illustration of the invention is by way of example, and the scope of the invention is not limited to the exact details shown or described.

Certain changes may be made in embodying the above invention, and in the construction thereof, without departing from the spirit and scope of the invention. It is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not meant in a limiting sense.

Having now described the features, discoveries and principles of the invention, the manner in which the inventive electrical connector is constructed and used, the characteristics of the construction, and advantageous, new and useful results obtained; the new and useful structures, devices, elements, arrangements, parts and combinations, are set forth in the appended claims.

It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described, and all statements of the scope of the invention which, as a matter of language, might be said to fall therebetween.

Claims (7)

1. A electrical connector for attachment to a workpiece (28) the workpiece having a void (26) therein to receive the electrical connector therethrough, said electrical connector (10) comprising:

a connector body (14) having a plurality of voids (18) therein,

a terminal (16) for insertion into each of said plurality of voids (18), said terminal being generally tubular and adapted to receive therein a male electrical connector, said terminal (16) having a spring clip (46) extending therefrom for connection to said connector body (14) for capture of said terminal (16) within said connector body (14),

a lip (58) extending from said connector body (14), said lip (58) being engageable with a surface of the workpiece (28) adjacent the void (26) to retain said connector body within said void and against said workpiece, and

a retainer clip (12) engageable with said lip (58) and said connector body (14) by insertion of a finger (32) into a cavity (30) on said connector body (14) whereby said lip (58) and said retainer clip (12) form a retainer collar for retaining said electrical connector within said void (26) of said workpiece (28).

2. The electrical connector as claimed inclaim 1 further comprising a groove in said connector body and a ridge extending from said retainer clip said ridge being mateable with said groove to reduce frontward and rearward motion of said connector with respect to said workpiece.

3. An improvement in a housing system for containing an electrical connector and for attaching the connector and housing to a workpiece, the connector housing being configured to be received within an opening or void or hole in a workpiece such as a semi-trailer frame and secured there to, the improvement comprising:

a lip (58) extending from a front edge of said connector body (14), said lip (58) being engageable with an edge of the workpiece (28) adjacent a void (26) to retain the connector body within the void, and

a retainer clip (12) engageable with said lip and said connector body (14) by insertion of a finger (32) into a cavity (30) on said connector body (14) whereby said lip (58) and said retainer clip (12) form a retainer collar for retaining said electrical connector within said void (26) of said workpiece (28).

4. The improvement as claimed inclaim 3 further comprising a groove in said connector body and a ridge extending from said retainer clip said ridge being mateable with said groove to reduce frontward and rearward motion of said connector with respect to said workpiece.

5. A method of installing an electrical connector on a vehicle, said vehicle having a surface thereon presenting a hole or void therethrough wherein said void or hole is accessible from both sides for performing the installation of the electrical connector, the surface having a first interior side and a second exterior side, the method comprising:

providing an electrical connector having an electrical connector body and a lip (58) extending from a front surface of the connector body (14), the lip (58) being engageable with an edge of the workpiece (28) wherein said edge defines a portion of the boundary of a void (26) in the workpiece

approaching the void with the electrical connector from the first interior side of the surface,

inserting said connector body within the void in the surface to position said lip on the second exterior side,

providing a retaining clip,

attaching the retaining clip to the connector body and to the lip to form a collar on the second side of the workpiece, and

attaching the connector body to the workpiece by securing the formed collar to the workpiece.

6. The method as claimed inclaim 5 wherein said connector is secured to the workpiece by passing at least one fastener through the formed collar and through the workpiece.

7. The method as claimed inclaim 5 wherein said connector is secured to the workpiece by an adhesive applied to the formed collar and the workpiece.

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